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Well thanks to the help of this msg board, I did some major work last night.

First thing was thermo sending unit that has kept me off the trails for a month while I waited for the right part. First, they sent the wrong thermo switch. The Yamaha diagrams have are wrong on the 2002 Grizzly 660. They mistakenly switched the part numbers on the diagram for the two thermo switches. Result was I got the wrong thermo in a bag with what the diagram says is the right part number. I can't believe in 3 years that I was the first person to realise this and it was never fixed before. Anyway, another week of waiting and I finally got the right one. Now on to fixing.. Well, we take the front hood off and remove the radiator cap and there is barely any coolant. We fill up with water and I see it pouring out by the left footrest. I get underneath and see a 1/2 inch stick right into the hose. Turns out, I hit this stick about 100 yrds from my house the last ride and all the fluid drained so quickly that the overflow resevoir still showed a full level. Then when I parked the quad in the garage, there was no fluid left to leak out so I never realized I had a leak!!! I followed all the diagnostics, but instead of taking the hood off and checking the radiator I assumed there was coolant because of the overflow resevoir.. DOH! The reason the thermo switch didnt turn the fan on is that it was not immersed in any coolant... Then 4 weeks later trying to get the stupid part and I dont need it after all!!! Now I have to wait one more week for the lower radiator hose... man I feel dumb! Shortcuts wasted a month of riding!

Next I did the valve adjustment. Suprisingly, they were not bad. The exhaust valves were right on the money and the intake valves were near the low end of the specifications so we adjusted them to the middle of specs. All in all they were very good considering no adjustment ever done and it has 185 hours and 1250 miles. Two notes on my experience.

Aligning TDC - There are actually 3 marks on the crankshaft! What was Yamaha thinking?!?! They say to align the I mark with the notch and then they put 3 marks on wheel. The first two marks (if rotating counter clockwise like the manual says) are connected with a line, while the third line is a stand alone mark. Our gut feeling was the 3rd line which is by itself, but to be sure we checked the piston position thru the spark plug hole and indeed it was the third line.

We were able to adjust the valves without removing the front fender. It was a pain and very difficult to see, but with two friends help, a mirror and light, I was able to sneak my head in far enough to check the exhaust valves. Luckily they were within specs... I am not sure how well we would have been able to adjust them with the fender still one and limited access.

Well, thats all for now. I hope to take some ride pics when I finally get back there!

Jim
 

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Sounds like a monster job! Congradulations!Done! May you not have to do any more maintenance for long-time. Chuck
 

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Sounds like you had some fun...lol In all seriousness it is real gratifying when you get all done and are able to look back and know that you did it all your self.

I decided my 01 Raptor need a new clutch and decided to do it my self. Took it all apart drained the oil, water and such. Installed the new clutch, oil, water and adjusted the cable. Start it up and let it warm up wile still on the stand I pull in the clutch and kick it in gear. What do you know, clutch is not working it is not disengageing. Now I have to go all through it again because I did not get the pressure plate all the way seated properly. Oh well not looking forward to it but when done I did it and next time I will try it before I add the oil and such. All in expercience just like your radiator hose. :)
 

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Jim, Each time you do the valves it will become easier, still a pain to do the exhaust but IMO not worth the time or trouble to take the front fender off. No need to get in there with a mirror you will be able to feel your way around.

A word of advise for everyone it to be very careful with the bolts that hold the recoil starter on because they will twist off easily. Currently I have one broken off with an ez out broken off inside the bolt also. My next valve adjustment I will have to figure out how I am going to get it out. Now when ever I pull any bolt that holds a cover on I use antiseize on the threads at assembly.
 

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Discussion Starter #5
"A word of advise for everyone it to be very careful with the bolts that hold the recoil starter on because they will twist off easily."

Wish you told me this a few days ago!!! I did break one of the bolts, thankfully it was on the housing and the others held it down pretty good. No idea how I am gonna get the rest of the bolt out though.

Jim
 

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I bought the feeler guage to do my valves but I am unsure about where exactly it goes. I've got my bike apart and the intake and exaust covers off. Does the feeler go right underneath the nut or what? Thanks, Ben.
 

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I imagine that you would have to ensure the valve is at BDC, then you place the feeler guage between the top of the valve and the rocker.

Hope this helps.

Cheers Noel
 

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I just got done with my second valve adjustment.. performed 1st one at 1200 miles exhaust ok intake valves were all tight.. This time around at 2500miles the machine was again tight on all intake valves.. Adj to .15 as I did before.. Never had a machine that valves would get tight.. The atv makes much less exhaust noise when running now.. it seams that the tight intake valves make the exhaust note when running have a louder pop to it.. I do not pull fenders off just fuel tank..
anyone else find intake get tighter clearence over time?
 

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iceman:

What year is your Grizzly? My 02's intake valves have gotten tight enough to need adjustment roughly every 30 hours since it was new. This was up until last year, at approximately 3500 miles. I'm within a hair of 4000 miles now, and I can finally go 2-3 oil changes between adjustemnts. I just did an adjustment the other day, after two oil changes without, and they were just a little tight. Exhausts were fine; I adjust those maybe ever 2000 miles ro so.

I have a set of intake valve springs from a Raptor that I've heard will cure the problem, but I haven't put them on yet. Kinda waiting til I finally break down and do a mild 686 with a Webcams cam. Wanna see if I can make this thing as fast as my new SP800EFI. :)

Rob
 
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